How to Know When It’s Best to Repair, Restore, or Replace Your Building’s Roof

A commercial roof shelters individuals, products, and infrastructure from environmental factors and plays a crucial role in managing energy consumption and expenses. However, like any building component, a roof will inevitably suffer damage or wear over time.

Determining whether to repair, restore, or replace a roof is a vital and complex decision. It can be a capital-intensive project, and your choices can determine if you extend the life of your building for a few or many more years. There are numerous factors that impact this decision, including the age of your building and roof; the current and future purpose or use of the building; whether you are required by code or want to include additional insulation; the extent of damage (if any); the type of roof you have; and your budget.

The team at Holcim Building Envelope has broken down some key considerations to help you make a more well-informed decision on whether repairing, restoring, or replacing is the best solution for you.

Inspection

Before determining the best approach for your roof, begin by evaluating your roof’s condition with a thorough inspection. Examine for tears, punctures, and areas with ponding water, and pay close attention to sections where rooftop equipment installations, including HVAC systems, have been placed. To ensure a thorough evaluation that goes beyond what is immediately visible, it is essential to consult a professional roofing contractor. Timely action is essential if any defects are present, such as weak spots or damaged seams, as they can lead to water leakage and increased vulnerability to wind and hail. Preventative inspections are critical to protecting one of your building’s largest assets, and to avoiding costly outcomes and business downtime.

Repair

Various repair options are available that cater to your specific roof type, ranging from liquid-applied sealants to materials that match the existing single-ply membrane. Patching the roof is a viable solution for minor leaks and limited damage. For more extensive leaks and permanent repairs, a full restoration or a complete tear-off and roof replacement may be necessary.

Restore

When deciding between roof restoration or replacement, a key consideration is how many more years of use you expect or need from the building. If you intend to extend the lifespan of your roof assembly by an additional 10-20 years and it is in good condition (requiring less than 25% repair), choosing a roof restoration through "recovering" or applying a restorative "maintenance" coating is a great option.

You should work with a licensed roofing contractor to understand your state’s roofing regulations, such as the number of roof cover layers that can be installed and the assembly height in relation to the surrounding walls. For instance, the 2021 International Building Code (IBC) restricts the number of roof cover layers to two. In other words, an existing roof assembly can only be “recovered” once for a total of two covers or membrane layers.

Recover

There are multiple options available for existing roofs that have only one cover layer. A common option is adding an additional roof membrane to prolong its durability without incurring the full cost of replacing the entire assembly. Recovering the roof provides advantages such as enhanced energy efficiency and added protection against the elements, which helps extend the roof’s lifespan.

For recovering projects, one popular roofing membrane material is Thermoplastic Polyolefin (TPO). TPO is cost-effective compared to other membranes and serves as a sustainable roofing solution for a wide range of commercial building types. TPO is also well suited to be installed around the complexities of the physical elements typically found on a roof (e.g., HVAC equipment, venting, etc.). While recovering will involve initial costs, it can yield long-term savings by reducing the frequency of roof repairs and reducing the cost of heating and cooling the building.

Restorative Coatings

For roofs that already have two cover layers or where adding an additional cover layer would be an overly complicated install, a “maintenance” coating system is a cost-effective solution to extend the life of a facility's roof. This option is especially beneficial when the alternative for a roof with two existing covers would be tearing off the entire assembly down to the deck and starting over, as required by the IBC. Coatings are considered a maintenance measure added to the existing roof covering. According to the IBC, coatings are not a new roof cover and may be reapplied through the life of the roof assembly.

As a maintenance system, coatings can sometimes be fully expensed in the year they are applied, allowing you to save money for other facility projects.[1]

Restorative coating systems offer several benefits, including waterproofing. Coatings provide self-flashing around roof penetrations and form a seamless, fully adhered monolithic layer, as well as eliminate seams and glues, which reduces the necessity for further detail work. Depending on your climate and specific roof needs, several coating options can be appropriate for maintaining your roof.

Maintenance coatings also offer the benefit of extending the roof’s life by up to 10-20 years by creating a protective barrier against UV rays, wind, and rain. They can also enhance the roof's appearance by covering existing damage or blemishes, resulting in a refreshed look.

Replace

When other solutions cannot meet your performance or longevity requirements, or if you have already reached the limit of recovering and restoration options (with two or more roofs/coating layers), replacing the roof is the final option. Also, if roof damage is widespread and visible, opting for a complete replacement can help prevent water damage, mold growth, and other related issues. If you choose to re-roof, it is important to have a professional roofing contractor inspect your roof to evaluate the potential options.

The benefits of a full re-roofing project start with superior protection from the elements. A new roof can enhance energy efficiency and reduce heating and cooling costs by bringing your building up to code. New developments in roofing insulation have led to increased energy savings and better temperature control. The choice of roofing material, whether dark or light-colored, can provide specific advantages depending on your region’s climate patterns.

Additionally, a new roof increases your building's value, making it more appealing to tenants responsible for heating and cooling costs, and giving your property the edge over buildings with older roofs. It also ensures peace of mind, particularly if a leak could negatively impact your business or tenant retention. In regions exposed to harsh weather conditions, the security offered by a sturdy roof is priceless.